CN103226151A - System and method for monitoring operation state of disc cutter group of cutterhead of tunneling machine - Google Patents
System and method for monitoring operation state of disc cutter group of cutterhead of tunneling machine Download PDFInfo
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Abstract
The invention discloses a system and a method for monitoring the operation state of a disc cutter group of a cutterhead of a tunneling machine. The method comprises the following steps: detecting the autorotation speed of each disc cutter by using a sensor; and transmitting a rotating speed signal to a computer in a control room of the tunneling machine by using a wireless data transmission device so as to judge the operation state of the disc cutters according to the rotating speed signal and the preset reference value relationship. The system and the method have the technical effect that the individual reference value of each individual of the disc cutter group is subjected to data processing and visual display, so that the operation state and the wear state of the disc cutter group of the tunneling machine can be displayed in real time. The monitoring system can provide selection help for an operator of the tunneling machine so as to determine whether to replace and maintain cutters or not, or change a tunneling control parameter to reach higher cutter group operation performance. By the method, manpower consumption can be reduced obviously, construction risk can be reduced, and work efficiency can be improved.
Description
Technical field
The present invention relates to a kind of tunnel boring machine monitoring system and method, relate in particular to a kind of cutterhead disk cutter colony running state monitoring system and method.
Background technology
In the tunnel excavation of growing up of Important Project such as railway, highway, water transfer, the rock crushing tool that development machine uses especially disk cutter is in continuous wear process.The development machine cutterhead is equipped with many identical or different cutter, and the state of wear of each cutter is relevant with its installation site and broken rock process (driving more renews cutter or knife part midway).If the single generation heavy wear in this cutter colony then can influence its cutter group overall performance (the whole rock breaking capacity of cutter group weakens), change this single cutter this moment is favourable.The realization of above-mentioned target depends on the monitoring of the individual running status of each cutter on the cutterhead.Therefore from the individual monitoring running state of cutter to cutter group overall operation status monitoring and to carry out control corresponding (comprise design, construction, monitor) be necessary.The state of wear of cutter individuality is judged by machine operator's visual inspection at present.For this reason, must stop machine (development machine every day carry out cutter maintenance).Then, the staff enters the excavation area and checks every cutting tool state with measurer.The state of wear of cutter is judged by the rotation symmetry of length wearing and tearing and wearing and tearing form.
CN202108517U discloses a kind of hobboing cutter device with wearing and tearing deixis, in this device, by being communicated to the inner chamber of blade from disk cutter cutter shaft end being provided with one, and will connect fuel transfer system.The blade wearing and tearing can make the inner chamber leakage of oil cause the fuel transfer system oil pressure to descend, and reflect the state of wear of hobboing cutter with this.Because this device blade has inner chamber, can reduce brokenly the lithology energy.
CN10227896A discloses a kind of development machine disk cutter wear extent and has estimated computing method, obtain the gyro frequency of disk cutter in the method by the acceleration change situation of measuring disk cutter, set up the corresponding relation formula between gyro frequency and the frictional work, finally obtained the corresponding relation formula between disk cutter acceleration signal and the wear extent.The reliability and the accuracy of energy mill loss rate data in this method dependence and the formula.
Summary of the invention
The object of the invention is to provide a kind of method: by the rotational velocity of sensor acquisition disk cutter individuality, adopt wireless transmit and accept hobboing cutter rotation tach signal to deposit in the microcontroller, upload to and carry out inventory analysis on the computing machine.Can realize monitoring the operating condition of disk cutter individuality in the development machine tunneling process and the function of cutter colony running status by this method.
This purpose realizes by following technical proposal, a kind of development machine cutterhead disk cutter colony operating state monitoring system, comprise the detection probe that is used to detect the hobboing cutter rotating speed, fore-lying device, wireless launcher, signal receiving device, development machine PLC control system and touch-screen, described detection probe is installed in the disk cutter cutter shaft, detection probe, fore-lying device, wireless launcher communicates to connect successively, wireless launcher communicates to connect by wireless mode and signal receiving device, described signal receiving device, development machine PLC control system and touch-screen communicate to connect successively.
Described a kind of development machine cutterhead disk cutter colony operating state monitoring system, described wireless launcher comprises the emitter microcontroller, emitter power module and emitter radio-frequency (RF) transceiver, described emitter power module is the power supply of emitter microcontroller, described emitter micro-controller communications connects the emitter radio-frequency (RF) transceiver, described emitter radio-frequency (RF) transceiver communicates to connect signal receiving device by wireless mode, the emitter micro-controller communications connects fore-lying device, described signal receiving device comprises the receiving trap microcontroller, the receiving trap radio-frequency (RF) transceiver, receiving trap power module and serial ports unit, described receiving trap power module is the power supply of receiving trap microcontroller, described receiving trap microcontroller communicates to connect receiving trap radio-frequency (RF) transceiver and serial ports unit respectively, the receiving trap radio-frequency (RF) transceiver communicates to connect wireless launcher by wireless mode, and the serial ports unit communication connects development machine PLC control system.
Described a kind of development machine cutterhead disk cutter colony operating state monitoring system, described detection probe is an acoustic signal sensor, the axial hole that has radial hole and be in a center on the described disk cutter cutter shaft, described radial hole is a shoulder hole, shoulder hole comprises a less unthreaded hole of internal diameter that is in after the disk cutter cutter shaft internal thread hole that radially internal diameter of outer part is bigger and are connected internal thread hole, signal transducer is fixed in the internal thread hole, the signal derivation line that is connected in the signal transducer tail end passes unthreaded hole, axial hole and radial hole connect in the corresponding shaft part of cutter ring center, sensor conductor is via shoulder hole, axial hole leads to axle head, and the inner spacer ring of described disk cutter radially has the circular hole that connects with internal thread hole so that sensor is installed.
Described a kind of development machine cutterhead disk cutter colony operating state monitoring system, described detection probe is an eddy current sensor, the axial hole that has radial hole and be in a center on the described disk cutter cutter shaft, described radial hole is a shoulder hole, shoulder hole comprises a less unthreaded hole of internal diameter that is in after the disk cutter cutter shaft internal thread hole that radially internal diameter of outer part is bigger and are connected internal thread hole, signal transducer is fixed in the internal thread hole, the signal derivation line that is connected in the signal transducer tail end passes unthreaded hole, axial hole and radial hole connect in the corresponding shaft part of cutter ring center, sensor conductor is via shoulder hole, axial hole leads to axle head, the inner spacer ring of described disk cutter radially has the circular hole that connects with internal thread hole so that sensor is installed, the boss surface of described Dao Grains inside surface has a plurality of evenly distributed teeth, detection probe over against the boss surface of Dao Grains inside surface when hobboing cutter rotates, to detect the motion of tooth.
In actual motion, tooth when hobboing cutter rotates on the boss surface of ， Dao Grains inside surface and between cog can alternately pass through the signal transducer sensed position, thereby obtain transducing signal.
A kind of method that adopts said system to monitor cutterhead disk cutter colony running status in the development machine tunneling process, utilize the individual rotational velocity n of each disk cutter of sensor, and should be sent to development machine pulpit computing machine by individuality rotational velocity n, and then according to individual rotational velocity n of disk cutter and the reference value n that prestores by wireless data transmission device
1Between relation, and then judge the running status of disk cutter.
Described method, individual rotational velocity n of the described disk cutter that is detected and the reference value n that prestores
1Between relation obtain by following formula:
S=(n
1－n)/n
1
Wherein S is the individual reference value, n
1=n
2R
2/ R
1, R
1Be disk cutter radius, R under the state of wear not
2For hobboing cutter is installed radius, n
2Be the cutterhead rotating speed.
Described method judges that the step of the running status of disk cutter is: given disk cutter wearing and tearing allowable limit value Δ h
0, when reference value S＜-Δ h
0/ R
1The time, the wearing and tearing of the individual generation of disk cutter excess are described; Reference value-Δ h
0/ R
1≤ S≤0 o'clock illustrates the individual normal operation of disk cutter; Reference value S＞0 o'clock illustrates that disk cutter is in the abnormal running state, string mill, stuck abnormal running state promptly may occur comprising.
Technique effect of the present invention is, carries out data processing and visualization display by each the individual individual reference value to disk cutter colony, can show the running status and the state of wear of development machine disk cutter colony in real time.This supervisory system can provide one to choose help for the development machine operating personnel.Corresponding therewith, he can determine whether to carry out cutter changing and maintenance, perhaps changes the driving controlled variable to reach better cutter colony runnability.Can significantly reduce the manpower consumption in this way, reduce construction risk, improve operating efficiency.
The invention will be further described below in conjunction with accompanying drawing.
Description of drawings
Fig. 1 is for being development machine cutterhead disk cutter of the present invention colony running state monitoring entire system block diagram;
Fig. 2 is a hobboing cutter integral installation figure of the present invention;
Fig. 3 is that sensor of the present invention is installed and signal derived type structure figure;
Fig. 4 is the structural drawing of disk cutter cutter shaft of the present invention;
Fig. 5 is the structural drawing of disk cutter Dao Grains of the present invention;
Fig. 6 is the structural drawing of disk cutter spacer ring of the present invention;
Fig. 7 is a wireless signal transmitting device schematic diagram of the present invention;
Fig. 8 is a wireless signal receiving trap schematic diagram of the present invention;
Fig. 9 is a screen displaying design sketch of the present invention.
1-cutter shaft among the figure; The 2-sensor; The 3-spacer ring; 4-Dao Grains; The 5-cutter ring; The 6-data line; The 7-fore-lying device; The 8-wireless launcher; The 9-signal receiver; The 10-PLC control system; The 11-touch-screen; The 12-digital control system; The 13-power module; The 14-radio-frequency (RF) transceiver
Embodiment
The present invention is the rotational velocity that obtains the disk cutter individuality by sensor, by the multiple signals integrating device each individual rotational velocity signal and position signalling in the cutter colony is stored in the storer, and this signal is transmitted into the development machine pulpit by wireless launcher.In the development machine pulpit wireless signal receiver is set, the individual rotational velocity signal of disk cutter (being called " individual measured value " below) of each road signal representative is stored in the computing machine, and compares with an individual reference value that is pre-stored in the storage unit.This individuality reference value is relevant with disk cutter installation site and cutterhead velocity of rotation.
According to the present invention, determine body reference value one by one by comparing individual measured value of disk cutter and individual reference value, this individual reference value comprises the quantitative conclusion of individual operating condition of relevant disk cutter and state of wear.
Carry out data processing and visualization display by each individual individual reference value, can show the running status and the state of wear of development machine disk cutter colony in real time disk cutter colony.This supervisory system can provide one to choose help for the development machine operating personnel.Corresponding therewith, he can determine whether to carry out cutter changing and maintenance, perhaps changes the driving controlled variable to reach better cutter colony runnability.Can significantly reduce the manpower consumption in this way, reduce construction risk, improve operating efficiency.
Individual reference value can be a prior known value or that detect and stored value or a characterisitic family or a funtcional relationship.
Possible arrangement form of the present invention can be set to, and existing disk cutter Dao Grains is carried out structural change, to help obtaining the tachometer value of disk cutter Dao Grains as individual measured value.
Under the simplest situation, the tooth of some is made in Zai Dao Grains side end face, and proximity transducer is installed on tool rest simultaneously, adopt the frequency measurement method or survey periodic method and measure Dao Grains rotating speed, Jiang the tachometer value of Dao Grains as individual measured value.Each disk cutter installed position is provided with sensor on cutterhead, obtains each individual measured value.
Except the tooth of some is made in Zai Dao Grains side end face, also can Zai Dao Grains inside surface make the tooth of some, and open installation and the lead that a cavity is used for tachogenerator in cutter shaft inside and draw.
Another possible arrangement form of the present invention can be set to, and the rotation situation of obtaining disk cutter inner circular taper roller bearing comprises that rotating speed, voice signal etc. are as individual measured value.
Under the simplest situation, on the inner cutter shaft of disk cutter, proximity transducer is installed, measure the taper roller rotational frequency and be converted into the velocity of rotation of taper roll bearing by the frequency measurement method.
Except the frequency measurement method tests the speed, can also judge the hobboing cutter rotational velocity with this at the inner sound frequency that acoustic signal sensor measurement taper roll bearing is installed of hobboing cutter.According to the bearing rotating speed of The Timken Company announcement and the frequency relation of voice signal, the signal that described sound signal sensing device is collected changes into the rotating speed of bearing, thereby obtains the individual rotational velocity of hobboing cutter.With reference to webpage:
http://www.timken.com/zh-cn/Knowledge/engineers/Pages/default.aspx
Preferred layout of the present invention can be set to, and offers the tooth of some at disk cutter Dao Grains inside surface, and offers one in cutter shaft inside and be used for the cavity that tachogenerator and lead are drawn, and is equipped with corresponding seal approach simultaneously.
If method is arranged to following form, the tachometer value that promptly obtains disk cutter Dao Grains is as the individual measured value of disk cutter running status, and so Yi Shang description can realize especially easily.
After this carry out collecting sensor signal and wireless transmission.Collecting sensor signal and wireless launcher comprise a microcontroller, a power module and a radio-frequency (RF) transceiver.Microprocessor controls to the rotating speed collection of each disk cutter on the cutterhead once, obtains the corresponding rotating speeds value at set intervals, stores.Radio-frequency (RF) transceiver sends packing data with RF-wise then, and whole process is controlled by microprocessor.Radio receiver is made up of microcontroller, radio-frequency (RF) transceiver, power module and serial ports.The radio-frequency (RF) transceiver received RF signal also stores in the microcontroller, through serial ports data transmission is arrived host computer then.Computing machine carries out inventory analysis to data, obtains the individual measured value (being designated as n) of each individuality in the cutter colony.
In this case, the further refinement of the running status of disk cutter individuality and state of wear can realize by following method, promptly obtain in dish type cutter diameter under the unworn new state, installation site radius and cutterhead rotating speed or the individual measured value, (be designated as n in the hope of individual reference value
1).
This reference value can be a theoretical value, because it can derive out by the disk cutter kinematic principle, also can be set to the individual measured value that obtains under new cutter state.
If this method is arranged to following form, promptly obtain not disk cutter radius R under the state of wear
1, the installation radius R on cutterhead
2And cutterhead rotation speed n
2, then individual reference value can be determined by following kinematic relation formula:
n
1=n
2R
2/R
1
N wherein
1Be the individual reference value of this disk cutter rotational velocity.
The individual running status individual reference of certain disk cutter value can be represented with following formula in this case
S=(n
1－n)/n
1。
In fact, consider or not the abnormal running state of the relative slip of disk cutter, the individual measured value n under its desirable running status under the disk cutter wear height Δ h situation with scar
3Determine by following kinematic relation formula:
n
3=n
2R
2/(R
2－Δh)
Wherein Δ h is the hobboing cutter wear height.
Hobboing cutter has relational expression under desirable normal operating condition
n=n
3
S＝(n
1－n)/n
1=(n
1－n
3)/n
1=－ΔhR
2/(R
1(R
1－Δh))≈－Δh/R
1
Consider that disk cutter allows greatest wear height Δ h
0, then have
0≤Δh≤Δh
0
R
2/(R
1－Δh
0)≤n=n
3=n
2R
2/(R
1－Δh)≤n
2R
2/R
1
－Δh/R
1≤S≤0
Following formula is designated as under the normal wear state, and disk cutter is in the individual reference value under the desirable running status.
The excess state of wear is
S≤-Δh/R
1。
Under the hobboing cutter abnormal running state relational expression is arranged
n≤n
1≤n
2
S＞0。
To sum up, S value and corresponding implication such as following table
The individual running status corresponding tables of table 1S value and disk cutter
| The S span | The hobboing cutter running status |
| S＜－Δh 0/R 1 | The wearing and tearing of hobboing cutter excess |
| －Δh 0/R 1≤S≤0 | Hobboing cutter normally moves |
| S>0 | The hobboing cutter abnormal running |
Computing machine obtains each individual running status of above-mentioned disk cutter colony, finish said process after, the running status of cutter colony is shown in real time by touch-screen.
Referring to Fig. 1,2, running state monitoring system of a kind of development machine cutterhead disk cutter colony.Disk cutter with monitoring running state function, in disk cutter cutter shaft 1, be provided with the detection probe 2 that is connected with fore-lying device 7 by data line 6, described fore-lying device 7 links to each other with wireless launcher 8, wireless launcher 8 arrives the data transmission that is detected the signal receiving device 9 of development machine pulpit, described signal receiving device 9 links to each other with development machine PLC control system 10, and PLC control system 10 is connected with touch-screen 11 and communication.
Wherein, described detection probe 2 is the electric vortex type speed probe, and probe 2 passes the hobboing cutter spacer ring 3 that has through hole, is threaded with hobboing cutter cutter shaft 1.Probe 2 coaxial wires of drawing are drawn from the cavity in the cutter shaft, link to each other with the prolongation cable by coaxial fitting afterwards, and signal is reached fore-lying device 7.
Referring to Fig. 3, described detection probe 2 adopts screw thread to be fixed on the threaded hole in axial step hole, derives line through axial hole derivation value axle head.
Referring to Fig. 4, the hole of the processing threaded hole of M8 and φ 6 is used for sensor 2 on the disk cutter cutter shaft installation and lead are drawn.
Referring to Fig. 5, corresponding, need to bore the hole of φ 10 on the hobboing cutter spacer ring 3 so that sensor passes.
Referring to Fig. 6, a kind of disk cutter Dao Grains 4 that detects the disk cutter rotating speed is the structural drawing after disk cutter Dao Grains is improved.The present invention processes the tooth of some at disk cutter Dao Grains inside surface, is assumed to 50 teeth, and modulus is 3mm, and length is 20mm, is choice criteria with the test request that can satisfy current vortex sensor 2.
Referring to Fig. 7, described wireless launcher 8 is made of microcontroller 12, power module 13 and radio-frequency (RF) transceiver 14.Wherein the major function of microcontroller 12 is the collection of disk cutter tach signal, processing, storage and control flow, and the major function of radio-frequency (RF) transceiver 14 is with RF-wise tach signal to be sent.
Referring to Fig. 8, described radio receiver 9 is made of microcontroller 15, radio-frequency (RF) transceiver 16, power module 17 and serial ports unit 18.Serial ports 18 mainly is to communicate with host computer, realizes the data of Single Chip Microcomputer (SCM) system and host computer.
The workflow of host computer can be described below: the signal that receives is converted into disk cutter actual speed (individual measured value n), with individual reference value (n
1) carry out computing and obtain individual reference value S, S=(n-n
1)/n
1Radius R by individual reference value S, disk cutter
1And the maximum numerical value that allows wear extent Δ h, judge the running status of this hobboing cutter according to table 1, and in touch-screen 11, show in real time.
Display effect in the touch-screen is referring to Fig. 9, and the running status of the hobboing cutter of each position all manifests in real time on the cutterhead, so that the development machine operator observes, determines whether tool changing or changes boring parameter.
Claims (7)
1. development machine cutterhead disk cutter colony operating state monitoring system, it is characterized in that, comprise the detection probe, fore-lying device, wireless launcher, signal receiving device, development machine PLC control system and the touch-screen that are used to detect the hobboing cutter rotating speed, described detection probe is installed in the disk cutter cutter shaft, detection probe, fore-lying device, wireless launcher communicate to connect successively, wireless launcher communicates to connect by wireless mode and signal receiving device, and described signal receiving device, development machine PLC control system and touch-screen communicate to connect successively.
2. a kind of development machine cutterhead disk cutter according to claim 1 colony operating state monitoring system, it is characterized in that, described wireless launcher comprises the emitter microcontroller, emitter power module and emitter radio-frequency (RF) transceiver, described emitter power module is the power supply of emitter microcontroller, described emitter micro-controller communications connects the emitter radio-frequency (RF) transceiver, described emitter radio-frequency (RF) transceiver communicates to connect signal receiving device by wireless mode, the emitter micro-controller communications connects fore-lying device, described signal receiving device comprises the receiving trap microcontroller, the receiving trap radio-frequency (RF) transceiver, receiving trap power module and serial ports unit, described receiving trap power module is the power supply of receiving trap microcontroller, described receiving trap microcontroller communicates to connect receiving trap radio-frequency (RF) transceiver and serial ports unit respectively, the receiving trap radio-frequency (RF) transceiver communicates to connect wireless launcher by wireless mode, and the serial ports unit communication connects development machine PLC control system.
3. a kind of development machine cutterhead disk cutter according to claim 1 colony operating state monitoring system, it is characterized in that, described detection probe is an acoustic signal sensor, the axial hole that has radial hole and be in a center on the described disk cutter cutter shaft, described radial hole is a shoulder hole, shoulder hole comprises a less unthreaded hole of internal diameter that is in after the disk cutter cutter shaft internal thread hole that radially internal diameter of outer part is bigger and are connected internal thread hole, signal transducer is fixed in the internal thread hole, the signal derivation line that is connected in the signal transducer tail end passes unthreaded hole, axial hole and radial hole connect in the corresponding shaft part of cutter ring center, sensor conductor is via shoulder hole, axial hole leads to axle head, and the inner spacer ring of described disk cutter radially has the circular hole that connects with internal thread hole so that sensor is installed.
4. a kind of development machine cutterhead disk cutter according to claim 1 colony operating state monitoring system, it is characterized in that, described detection probe is an eddy current sensor, the axial hole that has radial hole and be in a center on the described disk cutter cutter shaft, described radial hole is a shoulder hole, shoulder hole comprises a less unthreaded hole of internal diameter that is in after the disk cutter cutter shaft internal thread hole that radially internal diameter of outer part is bigger and are connected internal thread hole, signal transducer is fixed in the internal thread hole, the signal derivation line that is connected in the signal transducer tail end passes unthreaded hole, axial hole and radial hole connect in the corresponding shaft part of cutter ring center, sensor conductor is via shoulder hole, axial hole leads to axle head, the inner spacer ring of described disk cutter radially has the circular hole that connects with internal thread hole so that sensor is installed, the boss surface of described Dao Grains inside surface has a plurality of evenly distributed teeth, detection probe over against the boss surface of Dao Grains inside surface when hobboing cutter rotates, to detect the motion of tooth.
5. method that adopts said system to monitor cutterhead disk cutter colony running status in the development machine tunneling process, it is characterized in that, utilize the individual rotational velocity n of each disk cutter of sensor, and should be sent to development machine pulpit computing machine by individuality rotational velocity n, and then according to individual rotational velocity n of disk cutter and the reference value n that prestores by wireless data transmission device
1Between relation, and then judge the running status of disk cutter.
6. method according to claim 5 is characterized in that, individual rotational velocity n of the described disk cutter that is detected and the reference value n that prestores
1Between relation obtain by following formula:
S=(n
1-n)/n
1
Wherein S is the individual reference value, n
1=n
2R
2/ R
1, R
1Be disk cutter radius, R under the state of wear not
2For hobboing cutter is installed radius, n
2Be the cutterhead rotating speed.
7. method according to claim 6 is characterized in that, judges that the step of the running status of disk cutter is: given disk cutter wearing and tearing allowable limit value Δ h
0, when reference value S＜-Δ h
0/ R
1The time, the wearing and tearing of the individual generation of disk cutter excess are described; Reference value-Δ h
0/ R
1≤ S≤0 o'clock illustrates the individual normal operation of disk cutter; Reference value S＞0 o'clock illustrates that disk cutter is in the abnormal running state, string mill, stuck abnormal running state promptly may occur comprising.
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